Delayed release delivery system for laundry and other applications

ABSTRACT

A delayed release delivery system, comprising: a container for housing contents to be delivered; wherein the container is insoluble in water and sealable and comprises one or more conditionally sealed orifices; and a sealing member for conditionally sealing the one or more conditionally sealed orifices.

TECHNICAL FIELD

The disclosure relates to a delayed release delivery system, andspecifically to a container having a conditional sealable orifice, forexample, for laundry and other applications.

BACKGROUND

Throughout human history chemical additives, such as detergents, havebeen used in conjunction with mechanical agitation to clean clothing.More recently the powdered laundry detergents have been losing group toliquid agents and in particular to liquid agents in dissolvable laundrydetergent “pods.” However, while these “pods” appear to adequatelydisperse liquid laundry detergent they are not well suited toapplications that require the use of a dry powdered laundry detergent.When applied to a dry powder, the dissolvable pods do not adequatelydisperse the powder, which can lead to undesired clumping of thedetergent and unsightly residue left on clothing. Thus, new and improvedtechnologies are needed to aid in the dispersion of dry powderdetergents. Such improved technologies would also benefit otherapplications and industries where a dried substance needs to beadequately dispersed in a liquid environment.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be readily understood by the following detaileddescription in conjunction with the accompanying drawings and theappended claims. Embodiments are illustrated by way of example and notby way of limitation in the figures of the accompanying drawings.

FIG. 1 is a schematic showing an example of a delayed release deliverysystem having a vertical “U” shaped cut, in accordance with embodimentsdisclosed herein.

FIG. 2 is a schematic showing an example of a delayed release deliverysystem having a horizontal “U” shaped cut, in accordance withembodiments disclosed herein.

FIG. 3 is a schematic showing an example of a delayed release deliverysystem having a horizontal “U” shaped cut with stress relief corners, inaccordance with embodiments disclosed herein.

FIG. 4 is a schematic showing an example of a delayed release deliverysystem having a horizontal “X” shaped cut, in accordance withembodiments disclosed herein.

FIG. 5 is a schematic showing an example of a delayed release deliverysystem having a horizontal “O” shaped cut with stress relief corners, inaccordance with embodiments disclosed herein.

FIG. 6 is a schematic showing an example of a delayed release deliverysystem having a poly bag with fold-over seal, in accordance withembodiments disclosed herein.

FIGS. 7A and 7B are schematic drawings showing an example of a labelused for sealing die-cut bags of a delayed release delivery system, inaccordance with embodiments disclosed herein.

FIGS. 8A and 8B are schematic drawings showing an example of amultilayer label with water resistant surface and a patterned exposedpaper used for sealing die-cut bags of a delayed release deliverysystem, in accordance with embodiments disclosed herein.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which are shownby way of illustration embodiments that may be practiced. It is to beunderstood that other embodiments may be utilized and structural orlogical changes may be made without departing from the scope. Therefore,the following detailed description is not to be taken in a limitingsense.

Various operations may be described as multiple discrete operations inturn, in a manner that may be helpful in understanding embodiments;however, the order of description should not be construed to imply thatthese operations are order-dependent.

The description may use perspective-based descriptions such as up/down,back/front, and top/bottom. Such descriptions are merely used tofacilitate the discussion and are not intended to restrict theapplication of disclosed embodiments.

The terms “coupled” and “connected,” along with their derivatives, maybe used. It should be understood that these terms are not intended assynonyms for each other. Rather, in particular embodiments, “connected”may be used to indicate that two or more elements are in direct physicalcontact with each other. “Coupled” may mean that two or more elementsare in direct physical contact. However, “coupled” may also mean thattwo or more elements are not in direct contact with each other, but yetstill cooperate or interact with each other.

For the purposes of the description, a phrase in the form “A/B” or inthe form “A and/or B” means (A), (B), or (A and B). For the purposes ofthe description, a phrase in the form “at least one of A, B, and C”means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).For the purposes of the description, a phrase in the form “(A)B” means(B) or (AB) that is, A is an optional element.

The description may use the terms “embodiment” or “embodiments,” whichmay each refer to one or more of the same or different embodiments.Furthermore, the terms “comprising,” “including,” “having,” and thelike, as used with respect to embodiments, are synonymous, and aregenerally intended as “open” terms (e.g., the term “including” should beinterpreted as “including but not limited to,” the term “having” shouldbe interpreted as “having at least,” the term “includes” should beinterpreted as “includes but is not limited to,” etc.).

With respect to the use of any plural and/or singular terms herein,those having skill in the art can translate from the plural to thesingular and/or from the singular to the plural as is appropriate to thecontext and/or application. The various singular/plural permutations maybe expressly set forth herein for sake of clarity.

The current technology was developed to solve a problem of providing fordelayed release of powdered detergents into an aqueous medium, such asin a washing machine mid cycle. Water-soluble packaging such as PVOHfilms, labels, ties, etc. that are currently used in laundry pods andother products were found to be unsuitable for the delayed release ofpowdered detergents or other fabric care ingredients. For example thelow water temperature soluble bags instantly dissolved, which does notallow for delayed release. The bags rated for higher temperature openeda bit more slowly (not much), and would either take a long time to fullydissolve, which did not adequately disperse the contents, or they wouldleave behind a nasty wad of PVOH goop.

To overcome these deficiencies, disclosed are systems, articles ofmanufacture, and methods for the delayed release of a dry powder in aliquid environment, for example for laundry and other applications. Thedisclosed systems are particularly suited for any surface treatmentprocess for textiles or fabrics, for example, laundry, the applicationof epoxy-like coatings, dyeing processes, waterproofing, the applicationof antimicrobial/anti odor ingredients, the application of fireresistant coatings, and the application of mosquito repellant. Thedisclosed systems are amenable for use with multicomponent systems, suchas epoxies, where it would be possible to have more than one containerattached together each carrying one part of a multi-part system.

In embodiments, a delayed release delivery system includes a containerhaving one or more conditionally sealed orifices for housing contents tobe delivered. These conditionally sealed orifices are configured to openafter prolonged contact with an aqueous environment. A sealing member isused for conditionally sealing the one or more conditionally sealedorifices. The sealing member can be selected such that prolonged contactwith water causes the sealing member to weaken and allow the contents ofthe container to breach the seal, for example in conjunction withmechanical agitation of the container, such as might be found in awashing machine or mixing device.

The delayed release delivery system is typically configured so that thecontents of the container are released after the system has been exposedto water in a mechanically agitated environment for about 1 minute toabout 10 minutes, such as from 4 to 6 minutes, from 2 to 7 minutes, orfrom 1 to 5 minutes. Although, in some examples the delayed releasedelivery system is configured so that the contents are delivered at atime greater than 10 minutes. The delivery times can be adjusted basedon the application, for example in certain applications, such aslaundry, it may be advantageous to release the contents of the systemafter about 1 to about 5 minutes, while in other applications it may beadvantageous to release the contents of the container after a moreprolonged time, such as greater than 10 minutes.

A container for a delayed release delivery system is typically watertight and/or water resistant when sealed, for example to keep thecontents from getting wet until a desired time, such as after aparticular time that the delayed release delivery system is in contactwith water. In embodiments, the container is a non-soluble film bag orother soft/flexible water resistant packaging. In embodiments, thecontainer includes a laminate film packaging material, such as acommercially available laminate film packaging material, for examplevinyl pouches, low-density polyethylene (LDPE), olefin bags, and thelike. In embodiments, the laminate film packaging material comprises ofa sandwich of PET/Polyester/Polytheylene/Aluminum/polyethylene/LLDPE.

In embodiments, the container is a bag, sachet, and/or pouch and thesealing member is a pressure sensitive sticker that is applied to sealan orifice in the container. In embodiments, the container includes afront sheet, a back sheet, edges sealing the front sheet to the frontsheet such that the container defines a cavity disposed between thefront sheet and the back sheet for holding the contents to be delivered.In embodiments, the one or more conditionally sealed orifices include atleast one orifice in the front sheet. In embodiments, the one or moreconditionally sealed orifices include at least one orifice in the backsheet. In embodiments, the one or more conditionally sealed orificesinclude at least one orifice in the front sheet and at least one orificein the back sheet. In embodiments, the one or more conditionally sealedorifices include one or more flaps, which can be held in place by thesealing member, for example to cover the orifice (see, for example,FIGS. 1-5). The sealing member can be applied to the inside and/or theoutside of the container as needed. In other embodiments, there is noflap. In embodiments, the one or more conditionally sealed orifices arepresent on an edge of the container, which can be folded over and heldin place by the sealing member (see, for example FIG. 6). In versions ofthe container having a flap, the flap remains attached to the containerafter it bursts open and releases the contents.

The size of orifice can be variable relative to the size of thecontainer. In some specific examples, the container has a width of about4.85 inches and a height of about 6.25 inches. In some specificexamples, the orifice has a width of about 2.00 inches and a height ofabout 2.00 inches. In some specific examples, the sealing member has awidth of about 3.00 inches and a height of about 3.00 inches. As can beseen from FIGS. 1-5, there are variations on the shape and or size ofthe container and/or the orifice, for example an orifice with or withouta flap could be generally circular, ellipsoid, or some variation of apolygon. Even irregular shapes are envisioned within the scope of thisdisclosure.

One of the important factors in the choice of container and/or orificesize and/or relative size to one another. For example the size and shapecan be chosen so that when the sealing member is breached substantiallyall of the contents are released from the container, such is inside ofthe washing machine. Thus, the orifice should be selected to be largeenough to not impede any of the material from getting out.

In embodiments, a sealing member is selected that becomes weakened, forexample mechanically, when exposed to water, such that mechanicaltumbling, as one might find in a washing machine, facilitates rupture ofthe sealing member. By selection of the appropriate materials for thesealing member, the timing of this release can be effectively tuned suchthat the contents of the container are released at a desired time, forexample about 1 to about 5 minutes after starting a washing machine. Inembodiments, the orifice is configured so that substantially all of thecontents of the container are released upon opening of the orifice.

In embodiments, the sealing member includes a sticker and/or label whichis at least partially water soluble. In embodiments, the stickerincludes a face sheet, a backing material, and an adhesive, for examplelaid down in that order, wherein the adhesive is configured to couple tothe container. In embodiments, the sticker includes a permanent acrylicadhesive, a paper backing, and a surface coat. Typically this film orsticker is not intrinsically water soluble, but the paper backingrapidly loses any mechanical strength upon becoming wet or damp and isessentially abraded off during tumbling, such as might be experienced ina washing machine. In embodiments, the adhesive is not water soluble andstays behind on the container for easy removal. The tumbling action putsenough deformation on the container to cause the sealing member to fail.In embodiments, a combination of mechanical force and solubility of thesticker open the orifice and spill the contents. In embodiments, thesealing member is a sticker or label that comprises a surface finishoverlying a paper layer and permanent pressure sensitive adhesive underthe paper layer (see, for example FIGS. 7A and 7B). In some embodimentsthe sticker is a 2 mil thick paper sticker with a permanent acrylicadhesive and a surface top coat, for example that provides a mattefinish. In another embodiment, the sealing member is a sticker or labelthat has a water resistant frame (such as biaxially-orientedpolypropylene (BOPP)) surrounding a paper such as vellum whereby thepaper may or may not have an adhesive covering the cut, can absorb waterto become fragile (see, for example, FIGS. 8A and 8B).

In some embodiments, the top coat present on the top surface of thesticker can be selected to control, at least partially, the rate ofdisintegration of the label. In some embodiments, the top coat is avarnish, which provides texture, but it also seals/covers the papertemporarily controlling the rate of disintegration. In some embodiments,the top coating is chosen so that the contents are released in the firstapproximately 5 minutes after addition to the aqueous environment. Insome embodiments the topcoat for a matte or glossy finish is on theorder of 5-15 μm. These coatings are typically comprised of some polymerbinder and clay. The glossiness or matte finish is due to the relativemicroporosity of the topcoat and can be achieved with a wide variety ofmaterials. In addition, the compression of the paper as it rolls alsohelps to increase the density of both the paper and the coating.

In embodiments the contents of the container comprise a water soluble orwater dispersible powder, such as laundry detergent. In embodiments thecontents of the container comprise a bonding agent or activator thatwould be used as part of a two-part reaction such as an epoxy, dyeingprocess, textile surface coating process, or other surface treatment.The disclosed systems, and methods are particularly useful fordispersing particles, such as those compositions disclosed inInternational Patent Application No. PCT/US2016/059579, which isspecifically incorporated herein by reference in its entirety. Thus, insome embodiments, a disclosed delayed release delivery system includesone or more of the compositions disclosed in International PatentApplication No. PCT/US2016/059579.

In embodiments, the container comprises a first container and thedelayed release delivery system comprises one or more additionalcontainers for holding the same or different contents than the firstcontainer. In embodiments, the first container and the one or moreadditional containers are configured to burst at different delay times.In embodiments, the first container and the one or more additionalcontainers are configured to burst at the same delay times.

FIGS. 1-5 depict various examples of a delayed release delivery system,in accordance with embodiments disclosed herein. FIG. 1 shows a delayedrelease delivery system having a vertical “U” shaped cut. FIG. 2 shows adelayed release delivery system having a horizontal “U” shaped cut. FIG.3 shows a delayed release delivery system having a horizontal “U” shapedcut with stress relief corners built into the “U” shaped cut. FIG. 4shows a delayed release delivery system having a horizontal “X” shapedcut. FIG. 5 shows a delayed release delivery system having a horizontal“O” shaped cut with stress relief corners built into the “O” shaped cut.With respect to FIGS. 1-5, a delayed release delivery system 100includes a container 102, such as a bag, a pouch, or the like, having aheight H1 and width W1. In some specific examples, the container has awidth W1 of about 4.85 inches and a height H1 of about 6.25 inches. Inthe embodiments shown, the container includes a front sheet 104, a rearsheet (not visible in these views) opposite the front sheet 104, thefront sheet 104 and the rear sheet are sealed at edges 106, so as tocreate a sealed internal chamber or pocket that can be used to holdcontents to be delivered after a delayed time, for example from about 1minute to about 10 minutes after the delayed release delivery system hascontacted water. As shown, to deliver the contents of the container 102,the front sheet includes a conditionally sealed orifice 108, which, inthe embodiments shown in FIGS. 1-5 is formed by cutting the front sheet104 in a desired pattern at cut lines 110, for example by laser cuttingthe material in the desired pattern. The orifice 108 has a width W2 anda height H2 sized so as to essentially deliver all of the contents ofthe container 102 almost immediately once the conditionally occludedorifice 108 is opened. In some specific examples, the orifice has awidth W1 of about 2.00 inches and a height H2 of about 2.00 inches. Inthe embodiments shown in FIGS. 1-5, the front sheet 104 is onlypartially cut to form the orifice 108 and the orifice can be occluded bya flap 112, for example by holding the flap 112 in place for a timeuntil it is desirable to release the contents through the orifice 108.In the embodiments shown the flap 112 is contiguous with the front sheet104

In the embodiment shown in FIG. 1, the orifice 108 is vertically “U”shaped with rounded over corners. It is envisioned that these cornerscould be of various shapes, such as round, square, or even angled, suchas cut at a 45° or other angle. It is envisioned that in any of theembodiments, such as shown in FIGS. 1-5, that the rear sheet of thecontainer 102 can be identical in to the front sheet 104, for examplecut with an orifice 108 that is either identical or different in shapethan the orifice 108 of the front sheet 104.

FIG. 2 shows an embodiment where the orifice 108 is oriented with ahorizontal “U” shape. Also shown in this view is the presence of aconditional sealing member 120. The conditional sealing member 120 has awidth W3 (which in the embodiment shown is the same dimension, althoughnot necessarily, as the height), that is sufficient to cover the orifice108, such that the conditional sealing member 120 holds the orifice 108closed, for example during shipping and initial deployment. For examplethe conditional sealing member 120 can occlude the orifice 108 untilsuch a time as the contents should be delivered, at which time theconditional sealing member 120 ruptures to release the contents ofcontainer 102. In some specific examples, the sealing member has a widthW3 of about 3.00 inches and a height H3 of about 3.00 inches.

FIG. 3 shows an embodiment where the orifice 108 is oriented with avertical “U” shape. In this embodiment, the flap 112 further includesstress relief cuts 109 at the corners, for example, to keep the flap 112from ripping off during mechanical agitation, for example mechanicalagitation that may occur in a washing machine, such as a commercial orindustrial washing machine.

FIG. 4 shows an embodiment where the orifice 108 is formed from twocrossing cuts 110 oriented in an “X” shape. The “X” cut forms four flaps112 converging at the center of the orifice 108. Also shown in this viewis the conditional sealing member 120 (dashed line). The conditionalsealing member 120 covers all four flaps 112, keeping them closed untilthe correct time to deliver the contents.

FIG. 5 shows an embodiment where the orifice 108 has “O” shape. In thisembodiment, the flap 112 includes stress relief cuts 109 at the corners,for example, to keep the flap 112 from ripping off during mechanicalagitation, for example mechanical agitation that may occur in a washingmachine, such as a commercial or industrial washing machine. Also shownin this view is the conditional sealing member 120 (dashed line). Theconditional sealing member 120 covers the flap 112, keeping it closeduntil the correct time to deliver the contents.

FIG. 6 shows an alternate embodiment where the orifice 108 is formed inthe top of the container 102. In this view, a rear sheet 105 is visible.In this embodiment, the flap 112 is folded over the top of the container112 and held in place by the conditional sealing member 120, keeping thetop of the container closed until the correct time to deliver thecontents.

FIGS. 7A and 7B show a conditional sealing member 120 used for sealing adelayed release delivery system, in accordance with embodimentsdisclosed herein. FIG. 7A shows an example of a conditional sealingmember 120 used for sealing die-cut bags of a delayed release deliverysystem, such as shown in FIGS. 1-5. FIG. 7B shows a cross-section of aconditional sealing member 120 shown in FIG. 7A. The conditional sealingmember 120 has a width W3 and a height H3, that is sufficient to coveran orifice, such that the conditional sealing member 120 holds theorifice closed, for example during shipping and initial deployment,until such a time as the contents should be delivered, at which time theconditional sealing member 120 ruptures to release the contents of acontainer. The conditional sealing member 120 has a water resistantsurface 122, a paper layer 124, and an adhesive layer 126. In somespecific examples, the sealing member has a width W3 of about 3.00inches and a height H3 of about 3.00 inches.

FIGS. 8A and 8B show a conditional sealing member 120 used for sealing adelayed release delivery system, in accordance with embodimentsdisclosed herein. FIG. 8A, shows a front view of a conditional sealingmember 120, in accordance with embodiments disclosed herein. FIG. 8B,shows a cross-section of a conditional sealing member 120 of FIG. 8A.The conditional sealing member 120 has a width W3 and a height H3, thatis sufficient to cover an orifice, such that the conditional sealingmember 120 holds the orifice closed, for example during shipping andinitial deployment, until such a time as the contents should bedelivered, at which time the conditional sealing member 120 ruptures torelease the contents of a container. In some specific examples, thesealing member has a width of about 3.00 inches and a height of about3.00 inches. The embodiment shown in includes a “U” shaped region 129having an overall with W4 and overall height H4. In some specificexamples, the “U” shaped region 129 has an overall with W4 of 2.25inches and an overall height H4 of 2.00. The “U” shaped region 129 alsohas a channel width W5. In some specific examples, the sealing memberhas a channel width W5 of about 0.25 inches. The conditional sealingmember 120 has a water resistant surface 122, a paper layer 124, and anadhesive layer 126. The multilayer conditional sealing member 120 withwater resistant surface 122 and a patterned exposed paper layer 124 thatmay or may not have adhesive directly over the cut in channel 129 hasthe advantage of less paper ending up with the clothes and in the dryerfilter and not having the bag stick to a particular clothing item.

Although certain embodiments have been illustrated and described herein,it will be appreciated by those of ordinary skill in the art that a widevariety of alternate and/or equivalent embodiments or implementationscalculated to achieve the same purposes may be substituted for theembodiments shown and described without departing from the scope. Thosewith skill in the art will readily appreciate that embodiments may beimplemented in a very wide variety of ways. This application is intendedto cover any adaptations or variations of the embodiments discussedherein. Therefore, it is manifestly intended that embodiments be limitedonly by the claims and the equivalents thereof.

We claim:
 1. A delayed release delivery system, comprising: a containerfor housing contents to be delivered, wherein the container is insolublein water and sealable and comprises one or more conditionally sealedorifices; and a sealing member for conditionally sealing the one or moreconditionally sealed orifices.
 2. The delayed release delivery system ofclaim 1, wherein the container comprise a front sheet, a back sheet,edges sealing the front sheet to the back sheet and defining a cavitydisposed between the front sheet and the back for holding the contentsto be delivered.
 3. The delayed release delivery system of claim 1,wherein the one or more conditionally sealed orifices comprise one ormore flaps.
 4. The delayed release delivery system of claim 1, whereinthe one or more conditionally sealed orifices comprise at least oneorifice in the front sheet.
 5. The delayed release delivery system ofclaim 1, wherein the one or more conditionally sealed orifices compriseat least one orifice in the front sheet.
 6. The delayed release deliverysystem of claim 1, wherein the sealing member comprise a water solublesticker.
 7. The delayed release delivery system of claim 6, wherein thesticker comprises a face sheet, the backing material, and an adhesive.8. The delayed release delivery system of claim 6, wherein the stickercomprises a permanent acrylic adhesive, a paper backing, and a surfacecoat.
 9. The delayed release delivery system of claim 1, wherein thecontainer comprises a laminate film packaging material.
 10. The delayedrelease delivery system of claim 9, wherein the laminate film packagingmaterial comprises a layered structure ofPET/Polyester/Polytheylene/Aluminum/polyethylene/LLDPE.
 11. The delayedrelease delivery system of claim 1, wherein the orifice is configured sothat substantially all of the contents of the container are releasedupon opening of the orifice.
 12. The delayed release delivery system ofclaim 1, wherein a combination of mechanical force and solubility of thesticker open the orifice and spill the contents.
 13. The delayed releasedelivery system of claim 1, wherein the container comprises a firstcontainer and the delayed release delivery system comprises one or moreadditional containers for holding the same or different contents thanthe first container.
 14. The delayed release delivery system of claim13, wherein the first container and the one or more additionalcontainers are configured to burst at different delay times.
 15. Thedelayed release delivery system of claim 13, wherein the first containerand the one or more additional containers are configured to burst atsimultaneous delay times.
 16. The delayed release delivery system ofclaim 1, wherein the contents of the container comprise a water solubleor water dispersible powder.
 17. The delayed release delivery system ofclaim 1, wherein the contents of the container comprise a laundrydetergent.
 18. A method of delayed delivery of a water soluble or waterdispersible powder to an aqueous system, comprising: contacting theaqueous system with a delayed release delivery system, comprising: acontainer for housing the water soluble or water dispersible powder;wherein the container is insoluble in water and sealable and comprisesone or more conditionally sealed orifices; and a sealing member forconditionally sealing the one or more conditionally sealed orifices; andapplying mechanical agitation to the aqueous system.
 19. The method ofclaim 18, wherein the water soluble or water dispersible powdercomprises a laundry detergent.